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5S Technique and Kaizen - Er - Ashish Saxena
5S Technique and Kaizen - Er - Ashish Saxena
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Program Module
(Module-1) Introduction (Module-3) 5S and Teamwork
The 5S's 5S evaluation team
Benefits of 5S 5S Photography Team
How 5S Eliminates Waste
5S Mapping Teams
Red Tag Register & 5S
(Module-2) Putting 5S to work Board
Sort
Red Tag Movement (Module-4) 5S Project
Set in order
Executing the Project
Visual Tools Management Presentation
Shine
Standardize
Sustain
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What is Industry ?
Input Output
Industry
Man-power Products
Machines Services
Materials
Methods
(4M’s)
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KAIZEN is a feedback.
Input Output
Industry
KAIZEN
action
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Introduction
What is Housekeeping
The 5S's
Benefits of 5S
How 5S Eliminates Waste
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Housekeeping
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i.e.
“Place for every thing
&
Every thing in it’s place”
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Safety
Productivity Clean
Quality Environment
Good housekeeping
promotes
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Improved
Identification Discipline Searching productivity
System In Time and
in the the Is high
department department eliminated morale
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department,
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More importantly, they do not know how much they can gain
for themselves by just practicing good housekeeping.
Whether you work
the laboratory in an
or any office,
other thehousekeeping
place, factory, the warehouse,
is relevant
to you.
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Why do 5S ?
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Why do 5S ?
What is
5S ?
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5S stands for 5 initials
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words:
1. Sei-ri (Organization)
2. Sei-ton (Set in Order)
3. Sei-so (Cleaning)
4. Sei-ke-tsu (Standardization)
5. Shi-tsu-ke (Self-discipline)
5S OSCSS
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Translation
Japanese Translation Conversion
Seiri Organization
Sort
Seiton Neatness Set in Order
Seiso Cleaning
Shine
Seiketsu Standardization Standardize
Shitsuke Discipline Sustain
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5S Explanation
Sort
When in
doubt,
move it
out-
Red Tag
technique
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5S Explanation
Sort Set in
order
When in A place
doubt, For
move it everything
out- and
Red Tag everything
technique in its place
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5S Explanation
5S Explanation
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SORT SET IN
ORDER
(Organization) (Orderliness)
Clearly distinguish Keep needed items
needed items from in the correct
unneeded items SUSTAIN place to allow for
and eliminate easy & quick
(Discipline)
the latter retrieval
Make a habit
of
maintaining
This is the Keep the
established
condition we procedures workshop
support when swept and
we maintain the clean
first three pillars
STANDARDIZE SHINE
(Standardized (Cleanliness)
Cleanup)
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The 5S Ladder
Sort
Standardize
Management Cultural
Led Sustain
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Benefits of 5S
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Importance of 5S
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Prevent errors
QUALITY
Eliminate wastes
PRODUCTIVITY
Benefits of 5S
Teamwork and discipline
Organized workplace
Safer work environment
Reduces stress
Impresses customers
Reduces waste
Better handle on costs
More pleasant place to work
Supports other Building Blocks of Lean
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According to a survey conducted by the Hong Kong
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Rework Discard Repairable Unrepairable No Potential Use Potentially Useful Req Spl Disposal
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Putting 5S to work
Sort
Red Tag Movement
Set in order
Visual Tools
Shine
Standardize
Sustain
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1S
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1S Sort…. Seri….Organization…
Dictionary definition:-
To put things in order (or organize them) according to a
specific rule or principle.
Industrial definition:
To distinguish between necessary things and
unnecessary things , and getting rid of what you do not
need.
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1S Sort…. Seri….Organization…
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1S Sort…. Seri….Organization…
Definition:-
Remove from the work place
All the supplies, materials, tools and paper work
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1S Sort…. Seri….Organization…
Meaning
Sort:
Separate what is needed and what is not needed,
and keep only those things that are needed in the
workplace.
Discard unnecessary items.
Something used once a year would not be an everyday
item.
And we would not necessarily need all of the everyday
items at once; but if lost, a replacement would be
necessary.
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1S The Key to Sorting The 5 S Technique and Kaizen
Sort does not mean that you throw out only items that
you are sure you will never need.
Nor does it mean that you arrange things into neat,
straight patterns.
When you sort, you leave only the bare essentials.
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Three Questions To Ask During The 5 S Technique and Kaizen
Sort
1. ―What do I NEED at my workstation
to do the required tasks?‖
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1S Wastes Avoided by Implementing Sort The 5 S Technique and Kaizen
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1S The 5 S Technique and Kaizen
Method
Step-1
Make a clear standard for deciding what is necessary
(If not used in one year, take further measures - throw away.)
Things not used Throw away
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1S Method
The 5 S Technique and Kaizen
Step-3
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1S Method
The 5 S Technique and Kaizen
Step-4
Make sure that no unneeded things are
brought into the plant.
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1S Examples
The 5 S Technique and Kaizen
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1S Examples
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area.
– Determine the off-line storage location
for items that are seldom used.
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Is the item needed every day?
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Throw away
Stop bringing new, unneeded items into
the workcell!
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An effective visual method to identify these unneeded items is called red tagging.
An effective visual method to identify these unneeded items is called red tagging.
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A red tag is placed on all items not required to complete your job.
The 5 S Technique and Kaizen
Occasionally
outside of theused
workitems are moved
area while to a more
unneeded itemsorganized storage location
are discarded.
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Red Tag Example
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Red Tag “in action”
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Red Tag “in action”
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Red Tag “in action”
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Potential Failure Point #1
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We
nextdon’t
four need
steps.to go forward with the
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Results of Sort
The 5 S Technique and Kaizen
to work
• Quality improvements
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2S
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Definition:-
Every piece of equipment, storage location,
consumable, tool, etc. in the workplace must have a
home.
Arrange and identify everything for ease of use.
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The 5 S Technique and Kaizen
Meaning
Neatly place and identify needed work items. Designate a
place for every needed item so that anyone can find it
Always put things back in their designated spots
Make it so that new employees, people from other companies,
or people who seldom come to the plant can find things easily
Design a storage place that is well marked so that necessary
items can be taken out quickly and used easily
Create storage space that makes it easy to return things to
their places and see if they’re missing
If things are in order, time wasted due to searching is
eliminated.
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8/9/20192S Wastes Avoided by Implementing Set-In-Order The 5 S Technique and Kaizen
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2S Method
The 5 S Technique and Kaizen
Step-1
Straighten up thoroughly
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2S Method
The 5 S Technique and Kaizen
Step-2
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2S Method
The 5 S Technique and Kaizen
Step-3
Decide on how to place things
• There are many different ways of storing things such as: shelves,
boxes, lockers, and hanging. Storage should display items clearly for
easy identification and access. We welcome any ideas from each work
area.
According to function: storage places for objects with the same
function
According to product: organizing a set of objects necessary for a
certain product and placing them in one container or location.
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2S Method
The 5 S Technique and Kaizen
Step-4
Display
• Locate display in the storage area
• Display the actual item to be stored
• Label and identify the storage location of
each item
• Sign-out
of items sheets can be used to keep track
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2S Examples
The 5 S Technique and Kaizen
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2S Examples
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2S Examples
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Visual Tools
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Visual Tools
The 5 S Technique and Kaizen
•
Those working in a value stream can easily
see upstream and downstream process steps
and can react quickly to issues
• process
Supervisor/lead can easily monitor entire
and can quickly react to issues
• Operational metrics visible, real-time, to
operators
• Andon lights or mailbox flags indicate state of
equipment
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Standardize - Visual Control The 5 S Technique and Kaizen
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Standardize - Visual Control The 5 S Technique and Kaizen
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Visual Tools
The 5 S Technique and Kaizen
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Border
The 5 S Technique and Kaizen
• traffic lanes
• stationary items
• mobile items
• walkways
• surface items
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Border
The 5 S Technique and Kaizen
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Label
The 5 S Technique and Kaizen
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3S
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3S Shine…Seiso….Cleanliness… The 5 S Technique and Kaizen
Definition:-
tool
piece of equipment is swept, cleaned and free of
square foot on the floor grim, dirt and grease,
working surface
writing surface properly painted
and kept that&way
sealed,
piece of furniture
Wall
rest area ,meeting place, storage place
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3S Shine…Seiso….Cleanliness… The 5 S Technique and Kaizen
Ensuring
purposeequipment
of shine. is in usable condition is the primary
• Get rid of all garbage and dust from the work area
• Clean everything from the floor, the walls, the ceiling,
and even the opposite side of the fluorescent lights or
the inside of cabinets
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3S Shine…Seiso….Cleanliness… The 5 S Technique and Kaizen
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3S
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Method
The 5 S Technique and Kaizen
Step-1
First, get rid of all that dirt
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3S
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Method
The 5 S Technique and Kaizen
Step-2
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3S
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Method
The 5 S Technique and Kaizen
Step-4
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3S Examples
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3S
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Examples
The 5 S Technique and Kaizen
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3S
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Examples
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3S Results of Implementing Shine
The 5 S Technique and Kaizen
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4S
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4S
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Standardize…Seiketsu
The 5 S Technique and Kaizen
Standardize:
Become a role model for adhering to the standards of
the first three S’s and encourage others to follow them.
Make rules and procedures to promote a good work
environment until the first three S’s become everybody’s
second nature.
• Once the need to standardize becomes part of the
culture of our workplace, everyone in the plant will have
the discipline to follow through on what has been
decided.
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4S
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Standardize…Seiketsu
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being done”
• “Even if we make a tool board, no one returns
things to where they belong.”
• “Even if we decide on a place to put parts, it is
only followed for the first two or three days!
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4S
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Standardize…Seiketsu The 5 S Technique and Kaizen
STANDARDIZE
• Design
• I will design a product that has been decided, in the way that
it has been decided, on the day that it has been decided.
Production Work Place
• I process the designated material, with the designated
machine, following the pre-determined methods
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4S
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Standardize…Seiketsu The 5 S Technique and Kaizen
Materials
• I procure the decided materials, on the designated day, at the
decided price
Shipping
• I deliver the designated product on the decided shipping date
to the designated place.
Process Management
• Idelivery
do the production and the
date, following manpower
decidedplan by the decided
rules.
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4S
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Examples
The 5 S Technique and Kaizen
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5S
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5S Sustain.. Shitsuke….Discipline
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Definition:-
Create and maintain a favorable 5S atmosphere in the
work place.
Both management and operations have the responsibility
for sustaining 5S’s
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5S
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Step-1
Maintain 5-S awareness
• We need to be continually motivated to improve the
company and promote the 5-S program.
• Distribute a 5-S newsletter, 5-S posters, 5-S awards,
5-S motto, 5-S Day — always continuing to inspire
fresh, new enthusiasm
• Develop a trigger for implementing Improvement
activities
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5S
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Step-2
Create opportunities to improve the 5-S
Group tools to use are:
• 5-S observation tours
• Continuing Kaizen workshops
• Team and Management Audits using Workplace
Organization Tool
• Team and Management Audits using Cleaning and
Lubrication Standards and Visual Work Instructions
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Thank You
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